Bandit Build 5b

[TJS]

Bandit Build #5 was the orginal build on this bike a couple of years ago. It didn't sell, so time for a re-build aka Build 5b.
The plan:
1. CBR 929 with 1995 GSXR 750 Forks. This gives better trail and rake numbers. It has a 2mm additional offset when compared with the 1995 GSXR 750 triples.
2. Replace the RF 900 swingarm with a 1995 GSXR 1100 swingarm. This is 2" longer than the RF 900. Note here, the OEM Bandit swing arm is also 2" longer than the RF 900. I currently also use 1995 GSXR 750 "dog" bones on the rear linkage to raise the rear ride height along with the ride height adjustable Fox shock.
3. Replace new OEM coolant hoses with a silicone hose kit.
4. Check adjust valves.....maybe install GSXR 400 cams.
5. Freshn up carbs with new Needle Jets, Viton gaskets, float valves, and I;m looking at increasing the air inlet jet to 1.5 or 1.55; OEM is 1.45.......I really want to order the FCRs! But SUDCO can't get them and I have to order from the UK or Japan. I need the $Dollar to get a little stronger on the international market!
6. ???? a few tricks here and there...

[Squishy]

Looking good.. USD forks look awesome on the b400.

I'd change those white crash protectors though 

[TJS]

Valves adjusted and new valve cover gasket.

[TJS]

Silicone hoses and new clamps.

[Squishy]

[TJS]

Here you go...

[TJS]

Carb shield added....just waitng for carb parts from the Big Brown Truck!

[TJS]

I still couldn't/wouldn't break down and buy an ultra-sonic cleaner, so here we go with Kerosne.
Procedure I used:

Pour Kerosene into spray bottle
Spay outside and let soak for 5 minutes
Use paint brushes and toothbrush to clean
Spray outside clean
Spay inside carbs and bowls, soak for 5 minutes
Used brushes and cotton rags
Spray again til clean
Spray all with water hose
Spay all with WD-40, spray thru all vents too
Spay all with compressed air
Tomorrow, new float jets, seals, gaskets

[TJS]

Will add pics and specific part #'s later:
http://www.ronayers.com/oemparts/a/suz/50d3efd0f8700230d8b4b74d/carburetor

1. New Jet Needles #28-1 went in.
2. Red Rubber greased the diaphragms.
3. Viton seals on: floats, small ring for carb top http://litetek.co/Carb_Kit_Suzuki_GSF400.html
4. Increased 1.45 Air Jet to 1.50 #48-3
5. New Float Needle http://www.ebay.com/itm/161913291847?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT
6. I had already increased to a 35 pilot with no holes. Bought another set of 35 pilots with holes from local dealer. Got home to install, they were made with no slit for a screw driver or method to install. New set on order for Friday.
7. I am reinstalling the Factory Pro Stage III kit, I will use a 115 main, 2 clip from top on the Needle, 2 3/4 turns out on the Air Mix Screw as a starting point.

[PALERO]

Looks fantastic! Keep us updated.

After soaking my Bandit 400 carbs to clean them, I went out and bought a cheap ultrasonic cleaner from Harbor Freight in the US to do my other bikes.  It cuts down the work like crazy I tell you.

Let me know what hose kit you bought-- that is next on my list.
That carb shield looks great.

[TJS]

No time for garage lately, but finally ....
1. comparison or pilot jets, one with holes went in
2. old air jet out new one in. Hint: lube and heat to remove 20+ yr old parts
3. used floats and bowl gaskets from Canada kit, used Viton on float, air mix screw,

[TJS]

Factory Pro air mix screws
http://www.factorypro.com/Prod_Pages/prods41.html

[PALERO]

You have part and source for that carb shield?  Never seen something like that before.

[TJS]

You have part and source for that carb shield?  Never seen something like that before.

https://www.facebook.com/SimonFrancisServices/

[TJS]

Carbs on...carbs off...times 5!
Wouldn't idle, run, etc....excess air and gas
1. 35 Pilots with air holes turned out to be one problem, went back to regular 35 pilots, that helped
2. still will not run and excess gas, rechecked floats ( I suck at floats!), made some small changes, a little better.
3. RPM not dropping and will not take throttle with out cutting off, adjust air to 3 turns, then to 2 turns, ..nothing helps
4. changed main to 112
5. Waiting now to go back to oem 145 air jet
Here is how I drained the bowls each time.